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RD-fl134 169 COMPOSITE MATERIALS FOR MAXILLOFACIAL PROSTHESES(U) i/iFRANKLIN RESEARCH CENTER PHILADELPHIA PRH L HELLER ET AL. RUG Si FRC-R-C4842-4 DADi?-77-C-7959
UNCLASSIFIED F/6 6/5 N
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COMPOSITE MATERIALS FOR MAXILLOFACIAL PROSTHESES
Annual Progress Report
Harold L. HellerRobert A. Erb, Ph.D. DTIC
AUGUST 1981 2818ill SEC T E 0
B... Supported by
UNITED STATES ARMY MEDICAL RESEARCH AND DEVELOPMENT COMMANDFORT DETRICK, FREDERICK MARYLAND 21701
Contract No. DAMD 17-77-C-7059
Franklin Research CenterDivision of The Franklin Institute
20th Street and The ParkwayPhiladelphia, Pennsylvania 19103
Approved for public release; distribution unlimited.
LLJjThe findings in this report are not to be construed as an official
Department of the Army position unless so designated by otherauthorized documents.
UURFrankin Research CenterA Dmwon of The FranWdn Insucute 83 10 2T 056
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SECURITY CLASSIFICATION OF THIS PAGE ("Oen Date Entered)PAGE READ INSTRUCTIONS
REPORT DOCUMENTATION PBEFORE COMPLETING FORM
I. REPORT NUMBER 2. GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER
- / 1. 14. TITLE (and Subtitle) S. TYPE OF REPORT & PERIOD COVERED
Composite Materials for Maxillofacial Annual Progress ReportPostses 9 Aug. 1980 - 8 Aug. 1981
Prostheses G. PERFORMING ORG. REPORT NUMBER
A-C4842-47. AUTHORa) S. CONTRACT OR GRANT NUMBER(s)
Harold L. HellerRobert A. Erb, Ph.D. DAMD 17-77-C-7059
9. PuRFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELCMENT. PROJECT. TASK
Franklin Research Center AREA a WORK UNIT NUMBERS
20th St. & Benjamin Franklin Parkway 62775A.
Philadelphia, PA 19103 3SI62775A825.AB.063
It. CONTROLLING OFFICE NAME AND ADORESS 12. REPORT DATE
U.S.Army Medical Research and Development Command August 1981HQDA (SGRD- RMS) Fort Detrick 13. NUMBER OF PAGES
Frederick, Maryland 21701 22 pages14. MONITORING AGENCY NAME & ADDRESS(il dilerent from Controllin Office! IS. SECURITY CLASS. (of this report)
Unclassified
1Sa. DECLASSIFICATION DOWNGRADINGSCHEDULE
I6. DISTRIBUTION STATEMENT (of thie Report)
Aoed faPubli releoub-
17. DISTRIBUTION STATEMENT (o1 the abstract entered In BIock 20 i dilcrert from Report)
IS. SUPPLEMENTARY NOTES
19 KEY WORDS (Continue on reverse aide If necessary and Identify byv block number)
MAXILLOFACIAL PROSTHESES; PROSTHETIC MATERIALS: MICROCAPSULES:
SOFT FILLERS; ELASTOMER COMPOSITES
2,. ABSTRACT (Continue on reverse side It necesary and Identify by block number)
",The purpose of this program is to develop ultrasoft composite materialsto be used as fillers in the fabrication of maxillofacial prostheses.The projected systems are elastomeric-shelled, liquid-filled microcapsules.Improvements were made in the interfacial polymerization process, providingsealed capsules which do not inhibit the cure of matrix materials, andwhich do not harden with time. Further research is needed on larger-scaleprocessing, on making smaller capsules, and on the mechanical propertiesof the ransiles in titrce, . I
DD JAN,3 1473 EDITION OF I NOVSSISOBSOLETE
SECURITY CLASSIFICATION OF THIS PAGE (Wen Data Entered)
I
ABSTRACT
The purpose of this program is to develop ultrasoft composite materials tobe used as fillers in the fabrication of maxillofacial prostheses. Theprojected composite systems are elastomeric-shelled, liquid-filledmicrocapsules. Experiments continued on the interfacial polymerizationprocess, with spherical, sealed, capsules achieved. Diffusion of core liquidthrough the capsule walls has been reduced and the use of a tin catalyst haseliminated the cure inhibition of the matrix materials. Needs identified arebetter production methods, a reduction in capsule size and a catalyzed bathusing a solvent other than kerosene.
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FOREWORD
The concept behind this program is that a multiphase composite systemshould be able to simulate the mechanical properties of human soft tissuebetter than a homogeneous system could. The proposed composite of particularinterest consists of liquid-filled, elastomeric-shelled microcapsules heldtogether to form a deformable mass; this is to simulate the semi-liquidc ellular structure of human soft tissue.
The fourth year's program has been directed toward the elimination ofcure inhibition of the matrix elastomers, the elimination of the diffusion ofcore material through the urethane shells, and to some degree, the reductionof the capsule size. Cure-through over a period of time was a problem, andthis has been eliminated by reducing the skin forming time in the bath to twominutes. Excellent quality, nearly transparent microcapsules can be made insmall batches.
00Frankin Research CenterA iCoan of The FranJh Insu ulet
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CONTENTS
Section Title Page
ABSTRACT
FOREWO RD
1 INTRODUCTION. . . . . 1
2 DEVELOPMENT OF PRACTICAL TECHNIQUES FOR THE PREPARATION OFLIQUID-FILLED POLYURETHANE CAPSULES . . . . . . . 3
2.1 Summary . . . . . . . . . . . . 3.
2.2 Two-Stage Drop Interfacial Polymerization System. . . 4
2.2.1 External (Continuous) Phase . . . . . . 4
2.2.2 Interior (Droplet) Phase . . . .... 4
2.2.3 Interior (Droplet) Phase Formulation . .. . 5
2.2.4 Preparation of Interior (Droplet) Phase . .
2.2.5 Preparation of Polyurethane Capsules by
' - Drop Interfacial Polymerization . . . . 6
2.3 System Variables . . . . . . . . . . 6
2.3.1 Core Materials . . . . . . . . . 6
2.3.2 Batch Age . . . . . . . . . . 8
* 2.3.3 Bath Thickeners . . . • . . . .. . 8
2.3.4 Hicrocapsule Washing . . . . . .. . 9
2.3.5 Catalyzed Bath 10
3 REDUCTION IN MICROCAPSULE SIZE . . . . . . . 11
4 COMPATIBILITY WITH CASTABLE ELASTOMERS . . . . . 12
* : 5 MECHANICAL PROPERTIES . . . . . . . . .. . 14
*. 6 FUTURE PLANS . . . . . . . . . ; • • • 17
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FIGURES
Number Title Page
1 Polypropylene-Glycol Filled Microcapsules (2X) . . . . 7
.; 2 Cut Cross Section of Microcapsules in MDX 4-4210. . * 7
3 Compressive Properties of Urethane Microcapsules WithLiquid Cores . . . . . . . . . . .. . 15
-iv
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1. INTRODUCTION
The soft tissues in maxillofacial areas have complex mechanical properties,
and are difficult to replicate when preparing external facial prostheses. An
area in particular in which further improvement is needed in facial
prosthetics is in simulating the softness or "feel" of underlying soft
tissues. This is particularly important if some movement capability is
needed. The softest materials presently available are polymeric foams (which
have the disadvantage of taking a permanent set by loss of gas when
compressed) and gels (which are often unstable and sometimes lose internal
liquid by syneresis).
This program is studying a new class of materials for use in fabricating
maxillofacial prostheses: namely, liquid-filled, elastomeric-shelled
"* microcapsules. Conceptually, such a product is attractive for several
reasons: (1) the cells in the natural soft tissue are themselves composites
* of liquid (or semi-liquid) material in deformable shells; (2) the
liquid-filled microcapsules could be stable entities free from the syneresis
or gas-leakage of other soft materials; (3) the microcapsules could be stored
as such and used by the prosthetist as an ultrasoft filler to modify other
materials as needed.
In the first annual report the history of materials for maxillofacial
prostheses was reviewed. Many materials have been used, but in recent times
poly(vinyl chloride) plastisols, polyurethane compositions and silicones have
been used effectively in simulation of skin and external features.
In the second annual report, efforts toward producing microcapsules by
* two experimental approaches were described. One approach involved coaxial
extrusion of a catalyzed elastomer precursor and core liquid into a receiving
bath. The other approach involved the interfacial polymerization of
polyurethane around droplets of a core liquid suspended in a continuum
containing reactive materials.
At the end of the second year, the coaxial extrusion approach was
discontinued. The third annual report covers the further development of the
OFranlin Research CenterA Gmwof c Thtenn h III.ume
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interfacial polymerization process to the point where microcapsules could be
produced.
Work over the past year has included the successful switch to a tin
catalyst to eliminate cure inhibition of the matrix polymers and defining the
variables that affect the quality of the microcapsules.
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2. DEVELOPMENT OF PRACTICAL TECHNIQUES FOR THE PREPARATIONOF LIQUID-FILLED POLYURETHANE CAPSULESS
2.1 SUMMARY
An effective and flexible process has been developed for the preparation
of liquid filled polyurethane capsules of the type believed to be suitable for
use in preparation of polymer composite systems.
The new method utilizes a two-stage polymerization process in which a
fragile polyurea skin is rapidly formed around a liquid droplet by interfacial
* polymerization as the first stage. After initial skin formation, a
* polyurethane wall membrane having the desired physical properties is formed by
a slower, secondary process.
Capsules with strong, flexible wall membranes containing a variety of
.' internal phases have been prepared by this method. The procedure appears to
*" be readily adaptable to scaleup operations.
The urethane system selected for the capsule wall is of the
cycloaliphatic diisocyanate type used to produce low modulus, light stable,
elastomeric films. The liquid interior phase used at present for the
maxillofacial prosthesis application is a non-reactive polypropylene glycol
(Union Carbide Corp., PPG-2000).
Throughout most of this program, the core materials in the microcapsuleshad been found to slowly exude through the urethane walls. This problem had
been overcome by using a higher molecular weight core material and reducing
the curing time in the kerosene bath from over 20 minutes to two minutes.
Another problem solved in this year's work was the inhibition of the cure
of matrix.polymers from the presence of the amine catalyst used in the
isocyanate/polyol reaction. This catalyst has been replaced with a tin
catalyst which does not inhibit the cure of the matrix polymers.
In this report the present capsule forming system and the problems that
have been encountered are described in detail.
uuFranldin Research Center -3-A Omsson d The Frenon insaute
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2.2 TWO-STAGE DROP INTERFACIAL POLYMERIZATION SYSTEM
2.2.1 External (Continuous) Phase
Kerosene (Fisher, deodorized, 96 wt. %), 1,7 diaminoheptane (Aldrich
D1740-8, 1 wt %), and fumed silica (Cabot Corp., Cab-O-Sil M-5, 3 wt %) are
mixed with a high speed mixer to form a thickened exterior phase. The silica
thickener is required to control the rate of fall of the liquid droplets
through the exterior phase during the first stage of cure. The silica level
is dependent on the viscosity of the droplet phase. 1,7-diaminoheptane reacts
rapidly with the droplet to form a fragile "skin" which protects the capsule
during the polyurethane formation.
2.2.2 Interior (Droplet) Phase
The interior phase consisted of:
(B-1) a cycloaliphatic diisocyanate(B-2) a mixture of linear and chain-branched polyols capable of reacting
with (B-i) to form a polyurethane(3-3) a tin catalyst(B-4) an inert polar liquid(B-5) a trace of non-reactive dye (eosin) to facilitate identification of
the beads.
B-1 - Isocyanate
The isocyanate presently used is methylene-bis-(4-cyclohexylisocyanate)
(Desmodur W; Mobay). It is used in the manufacture of uon-discoloring
urethane. It is sensitive to water and humid air and must be stored under a
blanket of dry nitrogen. The stannous octoate catalyst (B-3) is added to the
isocyanate.
B-1 - Polyol Mixture
Pluracol P-2010, a Wyandotte diol (98.7 parts) and Pluracol PeP-450, a
Wyandotte triol (1.3 parts) are mixed to form a reactive polyol phase capable
of reaction with the isocyanate (B-1) to form a polyurethane. The polyol
mixture (B-2) is added to the catalyzed isocyanate (B-l).
-4-
1 anklin Research CenterA Dhison o The Fraflu i Ifgsume
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B-4 - Inert Polyol
The inert polyol core material presently used is polypropylene glycol
(PPG-2000; Union Carbide). The eosin dye (B-5) is added to this polyol to
improve the visibility of the microcapsules. The colored core material is
added to the urethane (B-2 + B-1,3).
2.2.3 Interior (Droplet) Phase Formulation
The basic interior phase formulation presently used for microcapsule
formation is as follows:
Isocyanate 99.8[ 72.7Stannous octoate 0.21
50
Pluracol PL-2010 98.7 27.3
Pluracol PeP-450 1.3J
PPG-2000 100.0 50Eosin traceJ
2.2.4 Preparation of Interior (Droplet) Phase
The catalyzed isocyanate is heated to 50*C and agitated by a magnetic
stirrer. The polyol phase is added in a dropwise manner at approximately onedrop per second. Since the isocyanate is sensitive to moisture the entire
, system is blanketed in dry nitrogen. The reaction appears to be nearly
complete within an hour after the addition of the polyols, but the batch
should not be used until the next day. The shelf life of this polyurethane is
about 10 days, but it is best not to use it beyond five days.
The colored liquid core material is added to the polyurethane phase and
thoroughly blended together. Due to the high viscosity of the urethane, air
bubbles are trapped in the mixture and must be removed. This is accomplished
by placing the batch in a vacuum for about 10 minutes. The bubble-free batch
should not be used for several hours, but after this time, it is stable for at
least four days.
19 n::nin Research CenterA Omsmin d The Frarnin institute
................................................................,-....-............... ,W,'_-m ................... :.
2.2.5 Preparation of Polyurethane Capsules by Drop-Interfacial Polymerization
The freshly mixed external phase (A) is placed in an open vessel
containing a suitably sized polypropylene mesh basket for collection and
isolation of the capsules.
The internal phase is charged to a motor-driven syringe fitted with asuitable needle (a short 22 gauge needle was found to be suitable for many
preparations, but other sizes can be used).
The internal phase is added dropwise to the curing bath with the needle
tip approximately 4-8 cm above the bath surface. A variable speed turntable
• .. may be used to rotate the curing bath to provide a fresh surface for each
droplet.
The droplets immediately form a fragile (polyurea) skin. They are
allowed to remain in the curing bath for 2 to 3 minutes and then removed from
the bath (via the mesh basket). They are rinsed in kerosene followed by a
quick rinse in a dilute nonionic detergent solution (1% Triton X-100, Rohm and
Haas Company). They are then removed from the basket, dried, and stored in a
closed jar.
Figure 1 shows an example of the capsules made by the process mentioned
above. Note that these capsules (shown at 2X) have nearly transparent shells,
and that many have tails, some as long as twice their diameters. These tails
do not present a problem in handling the capsules and should not interfere
with the matrix polymers.
The tendency for tails to form is the result of the viscosity of the
urethane increasing with age and/or dropping the drops from an insufficient
height.
2.3 SYSTEM VARIABLES
2.3.1 Core Materials
The standard core material in the past year had been UCON fluid LB-385, a
polyalkylene glycol. It had been noticed that fresh batches of the prepolymer
1TRFtanfin Research Center -6-*A Omsian of The Frenkhn Inwvto
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Figure 1. Polypropylene-Glycol Filled Microcapsules (2X)
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Fiur 2 .Cut. Cross Sectio o.f Mi ,..pse in MD 4-421 12X)
A O"' ,%n of'.. he. -ran.hn ,I. ,, o;:
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Figure 1. Polypropylene -ycol File . icroapules.(.
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and the LB-385 produced poor quality microcapsules, but after standing for
several days, much better quality beads could be made. There appeared to be a
delay in complete mixing which could be seen by the slow development of the
eosin dye in the mix. On the other hand, the LB-385 is miscible with the
kerosene and causes a weak seal at the top of the microcapsule.
In order to overcome the miscibility problems, polypropylene glycol (PPG)
was evaluated as a core material. Using PPG, fresh batches could be used
within several hours, and the weak point at the tail end of the capcules was
eliminated. Although the bleeding out of the core material was greatly
reduced with the two minute time limit in the bath, this problem still
remained on long-term aging with the LB-385. A series of PPG liquids was
evaluated using a range of moleculat weights from 425 to 2000. The degree of
bleeding correlated well with the PPG molecular weight. The MW limit of 2000
gave the best results, but due to its high viscosity, larger drops are
formed. Also, the rate of flow out of the needle must be carefully
controlled, since higher rates produce an unbroken strean of the urethane
going into the bath.
2.3.2 Batch Age
The prepared urethane batches are not stable and start to gel in about 7
days. Up until this time, they can be successfully used. There is a shorter
shelf life for the urethane after the core material is added. Gelling does
eventually occur, but the quality of the microcapsules is reduced by the
seventh day of shelf life. As mentioned earlier, fresh batches need to be
aged several hours before using.
2.3.3 Bath Thickeners
The kerosene bath is thickened with fumed silica to prevent the
microcapsules from hitting the bottom of the container when they are dropped
into it. HiSil 600 )iad been used in the past, but Cab-O-Sil M-5 is now used.
The M-5 is clearer and disperses more readily in the solvent.
1' rnkfin Research Center -8-A Oiluo of The Frarnkho Insit4@
Now that a higher molecular weight core material is used, the droplets
must be released from a greater distance above the bath to allow the tails to
contract before passing through the surface. Four to eight centimeters above
the bath is about ideal, and three percent Cab-O-Sil is about the ideal
concentration. Higher concentrations were tried to eliminate the tails, but
this caused irregular shell surfaces that had thin spots. The three percent
level allows for some settling so that the drop initially comes in contact
with the pure solution, forms a skin, and then comes to rest in the Cab-O-Sil
layer.
2.3.4 Microcapsule Washing
After the microcapsules are removed from the bath, they must be washed,
chiefly to get rid of the kerosene. They are first rinsed in clean keroseneto remove any Cab-O-Sil and remaining diaminoheptane. From this point,
different methods have been used. The earlier approach was to quickly washthe microcapsules in an aqueous detergent solution followed by drying them on
a paper towel.
Alcohol washing has been found to be unsatisfactory due to softening of
the shells. ThL present technique used is to store the microcapsules in
polypropylene glycol (PPG-425) after the kerosene rinse. The microcapsules
are dumped out of the basket onto a paper towel to drain off excess kerosene,
-" and then placed in the PPG for storage until the production run is finished.
Storage in the PPG allows further curing without sticking together. This bathalso removes any stray diaminoheptane by chemically reacting with it, forming
a solid that is easily removed.
An interesting approach was tried for a continuous production technique
which utilized a two layer bath. The lower layer consisted of PPG and the
upper layer of slightly thickened kerosene containing diaminoheptane, and
. having a depth great enough to provide sufficient cure as the microcapsules
*. pass through it. Unfortunately, the diaminoheptane gradually reacted with the
PPG and formed a barrier at the interface.
UUUUFrankin Research CenterA DOmon d The FrankJn instiute
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The microcapsules can remain in the PPG for one day, but then should beremoved and washed with water and dried for future use. Other solvents
evaluated for washing include toluene and petroleum ether. Toluene issatisfactory and eliminates the need for a water wash. Petroleum ether, at
this time, appears to be an excellent solvent wash.
23.5 Catalyzed Bath
The diaminoheptane appears to have a limited solubility in the kerosene,
but up until recently, no problems were encountered from this. Recently itbecame time to produce larger batches of the microcapsules for composite
testing, but it was found that the larger the single batches were produced,the poorer the quality of the microcapsules became, particularly in the shell
elasticity.
This indicates that an insufficient amount of catalyst is available for a
complete cure when a large number of droplets are released in the bath. Thissuggests the need for a solvent other than kerosene which itself has in the
past been a problem.
Preliminary tests show that petroleum ether readily dissolves the
diaminoheptane, thickens well with Cab-O-Sil and produces tough smallerdiameter capsules than those formed in kerosene. The cure rate in thepetroleum ether is so rapid, it is possible to remove the microcapsules from
* the bath within a half minute.
Petroleum ether evaporates rapidly and may cause some handling problems,
which need to be considered.
, -10-UU"Franklin Research Center
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3. REDUCTION IN MICROCAPSULE SIZE
By the present method of production, the capsule size is held nearly
constant by the viscosity and capillarity effects that come into play when a
drop falls free from the tip of the needle. The needle size has only a minor
effect on the capsule size which is generally two millimeters in diameter.
Two air systems were tried for reducing the drop size. The first system
was designed to produce jets of air around the flat tip of the needle to blowoff small drops. The air was directed at the tip in a steep angle to force
the drops away from the tip. This process did not blow off the liquid in
small droplets, but removed the liquid in a spray mist.
The second approach tried was to inject the air into the liquid streamback inside the needle, but this too only removed the liquid in a spray mist.
From observing these processes, it was believed that the liquid drop mustbe completely out of the tube before it could be knocked away. Thus, by
extending a tip down one side of the needle, it was thought that it might bepossible to blow some of the liquid free from the free hanging drops. Again,
this approach did not work.
One other approach tried was to disperse the urethane into small droplets
in a liquid in which the urethane and core material are not soluble, and thendumping this mixture into the diaminoheptane bath. This approach has shown
some success using silicone oil (Dow Corning 200) as the dispersing liquid.
For a given batch, microcapsules in various sizes ranging from 0.3 to 1.5 mm
in diameter were produced. These microcapsules cured through to solid beadsin several days. It is possible that this method can be further improved, but
at this time the variables affecting the quality of the microcapsules are bestobserved and controlled by the single drop production method.
100@ranklin Research CenterA b. . ... of The Frorimn institute
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4. COMPATIBILITY WITH CASTABLE ELASTOMERS
Up until this year, the microcapsules could not be used in bulk with
castable elastomers due to the cure inhibition of the matrix elastomers by the
amine curing agent used in forming the polyurethane. To avoid this problem we
have switched to tin catalysts. Dimethyltin was found to be unsatisfactorydue to its incompatiblity with the diaminoheptane. Stannous octoate was found
to be ideal. In small quantities (0.2%) it provides a fast method forproducing urethanes that do not inhibit the cure of the microcapsule shells.
Matrix elastomers of Dow Corning MDX 4-4210 Clean Grade Elastomer,*! Silastic 382 Medical Grade Elastomer and RTV 3145 can now be used without
inhibition from the urethane catalyst. Figure 2 shows a cut cross section ofcapsules imbedded in MDX 4-4210.
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5. MECHANICAL PROPERTIES
An improved testing device was built for measuring the mechanical
properties of single capsules and capsule composites. The new device utilizes
a piezoelectric crystal for measuring the load applied to a bead. This device
has the advantage of being much more sensitive than the strain gauge system
previously used. This system also as the advantage of an internal constant
-: calibration, and it uses a non-bending platen. Furthermore, the platen is
large enough to test cubes of capsule filled composite materials. The strain
.* gauge arrangement previously used was operated at its maximum output which
yielded a full scale readout of 400 grams. The piezoelectric device is used
at an output level well under its full capacity. It was found that a full
scale reading of 100 grams is about ideal for our present capsules.
- The need for a better measurement technique resulted from our
requirements to measure small changes in the compressive strength of the
microcapsules as they age.
We are now able to calculate the forces applied to a single spherical
capsule. All previous results were reported only as the applied load. The
problems encountered with measuring the force per unit area was that the area
of the contact surfaces of the capsules increased with increasing load. To
overcome this problem, Dr. J. Stuart of Franklin Research Center (FRC) derived
an equation for determining the radius of the contact surface for elastic
spheres under compression. This equation is given below.
B "(1.3R _ O.013d2) 1/2 0.393d
where B is the radius of the contact surface, and:
R - the original radius of the sphere before compressiond - the distance between the compression plates.
An example of the results obtained by using the new compression rig and
calculating the applied forces using the above equation is shown in Figure 3.
The results obtained in this figure are averaged from five microcapsules taken
from batch 149-9.
-13-UOUUkra'kin Research Center
A Om ncw o The Frterin Inauute
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250
200
cc
150
1000
50
0 5 10 15 20 25 30 35 40' 45 50 55 60
DEFLECTION (percent)
Figure 3. Compressive Properties of Urethane MicrocapsulesWith Liquid Cores
-14-
VVtld~kin Research CenterA D-m of Th* Fuanhin Insolute
Microcapsules from this batch have been tested over a two month period,
starting with microcapsules only several hours old. Over this time period
there appears to be no perceptible changes in softness and elasticity of the
urethane shells.
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6. FUTURE PLANS
The major problem encountered a year ago was the izability to define the
variables that had an adverse effect on capsule quality. Now that these
variables are much better understood and can be controlled, future work should
advance significantly.
Four areas in which further work needs to be done are as follows:
1. Reduction in Microcapsule Size
To be used as a practical filler system, the diameter of the capsules
should be substantially less than the thickness of the 7rosthetic structure to
be fabricated, the present capsules, at about 2 mm in iiameter, are too large
for most applications. Efforts will be made to prepare capsules in diameters
of 0.5mm and less. Approaches which will be considered are: using smaller
diameter needles (than the present 22 gauge) for droplet formation, employing
vibration techniques to produce smaller droplets, and disgersions in neutral
liquids.
2. Advanced Production Methods
The present production method is ideal for ulaking emperimental batches,but not efficient enough to produce large quantities of 13he beads. We have
not been working in this area, since the approach to be Uaken will depend
somewhat on the method finally adopted for making the mxrocapsules. Three
possible approaches include (1) multiple containers on a rotating table, (2)
removal from the bath by a continuous belt, and (3) coniinuous bottom draining
through a filter and recirculation of the liquid back iVD the top of the bath.
3. Improved Diaminoheptane Bath
The use of kerosene as the liquid portion of the b~ch has presented some
problems with the rate of production and the permeabili, of the capsule
shells. Other bath liquids such as petroleum ether will be evaluated.
1 FnWIn Research Center -16-A Oom 0 The Fiandn Ilsauite
ANN -.
4. Composites
It is now possible to produce composites without cure inhibition of thematrix polymer. The limiting factor now is the present production rate. With
increased production, various composites will be made and mechanically tested.
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